Production of Aromatics from Methanol Using Selective Hydrogen Combustion

Abstract

A catalyst system and processes for combined aromatization and selective hydrogen combustion of oxygenated hydrocarbons are disclosed. The catalyst system contains at least one aromatization component and at least one selective hydrogen combustion component. The process is such that the yield of hydrogen is less than the yield of hydrogen when contacting the hydrocarbons with the aromatization component alone.

What is claimed is: 
     
         1 . A catalyst system comprising: (1) at least one aromatization component for converting oxygenated hydrocarbons to aromatic compounds and (2) at least one selective hydrogen combustion component for reacting hydrogen with oxygen, said selective hydrogen combustion component consisting essentially of (a) a metal combination selected from the group consisting of:
 i) at least one metal from group 3 and at least one metal from groups 4-15 of the Periodic Table of the Elements;   ii) at least one metal from groups 5-15 of the Periodic Table of the Elements, and at least one metal from at least one of groups 1, 2, and 4 of the Periodic Table of the Elements;   iii) at least one metal from groups 1-2, at least one metal from group 3, and at least one metal from groups 4-15 of the Periodic Table of the Elements; and   iv) two or more metals from groups 4-15 of the Periodic Table of the Elements   and (b) at least one of oxygen and sulfur, wherein the at least one of oxygen and sulfur is chemically bound both within and between the metals.   
     
     
         2 . The catalyst system of  claim 1 , wherein the selective hydrogen combustion component is a combination of metal combination (a)(i) and (b) at least one of oxygen and sulfur. 
     
     
         3 . The catalyst system of  claim 2 , wherein the at least one selective hydrogen combustion component comprises one or more of Y a In b Zn c Mn d O x±δ , La a Mn b Ni c Al d O x±δ , La a Mn b Al c O x±δ , Sc a Cu b1 Mn c O x±δ , Sc a Zn b Mn c O x±δ , La a Zr b O x±δ , Mn a Sc b O x±δ , and Pr a In b Zn c O x±δ , where a, b, c, and d are each between 0 and 1, the sum of a through d equals 1 to 3, x is the sum of a through d plus 1, and δ is the vacancy concentration or excess oxygen concentration. 
     
     
         4 . The catalyst system of  claim 1 , wherein the selective hydrogen combustion component is a combination of metal combination (a)(ii) and at least one of oxygen and sulfur. 
     
     
         5 . The catalyst system of  claim 4 , wherein the at least one selective hydrogen combustion component comprises one or more of K a Ba b Mn c O x±δ , K a Mg b Mn c O x±δ , Na a Mg b Mn c O x±δ , Mn a Mg b O x±δ , K a Sr b Mn c O x±δ , In a Ca b Mn c O x±δ , Bi a Ca b Mn c Co d O x±δ , Bi a Ca b Mn c Ni d O x±δ , Ca a Mn b Sn c Co d O x±δ , In a Mg b Mn c Al d O x±δ , In a Zn b Mn c Al d O x±δ , Na a Ba b Mn c O x±δ , Na a Co b Mn c O x±δ , Ca a Mn b Sb c O x±δ , Ca a Mn b Co c Al d O x±δ , Sr a Sb b Sn c Mg d O x±δ , K a Co b Mn c O x±δ , Mn a Mg b O x±δ , Ni a Mg b Mn c O x±δ , Mn a Mg b Al c O x±δ , Mn a Mg b Ti c O x±δ , Sr a Sb b Ca c O x±δ , Sr a Ti b Sn c Al d O x±δ , Sr a Mn b Ti c Al d O x±δ , Ca a Mn b O x±δ , Ca a Mn b O x±δ , Ca a Znr b Al c O x±δ , Bi a Ca b Mn c O x±δ , Bi a Sr b Co c Fe d O x±δ , Ba a Mn b O x±δ , Ca a Mn b Al c O x±δ , Ca a Na b Sn c O x±δ , and Ba a Zr b O x±δ , where a, b, c, and d are each between 0 and 1, the sum of a through d equals 1 to 3, x is the sum of a through d plus 1, and δ is the vacancy concentration or excess oxygen concentration. 
     
     
         6 . The catalyst system of  claim 1 , wherein the selective hydrogen combustion component is a combination of metal combination (a)(iii) and at least one of oxygen and sulfur. 
     
     
         7 . The catalyst system of  claim 6 , wherein the at least one selective hydrogen combustion component comprises one or more of La a Ca b Mn c Co d Ti e O x±δ , La a Ca b Mn c Co d Sn e O x±δ , La a Ca b Co c O x±δ , La a Ca b Mn c Ni d O x±δ , La a Ca b Mn c Co d Sn e O x±δ , La a Ca b Mn c Co d Al e O x±δ , La a Ca b Mn c Co d O x±δ , Ba a K b Bi c La d O x±δ , La a Ca b Mn c Ti d Al e O x±δ , La a Ca b Co c Ni d Al e O x±δ , La a Ca b Co c Ti d O x±δ , La a Ca b Mn c O x±δ , Ba a Bi b La c O x±δ , La a Ca b Mn c Mg d O x±δ , La a Ca b Mn c Fe d O x±δ , La a Sr b Co c Al d O x±δ , Ba a Bi b Yb c O x±δ , La 8 Ca b Mn c Ga d O x±δ , La a Ca b Mn c Sn d Al e O x±δ , La a Ca b Mn c Cu d O x±δ , La a Ca b Mn c Co d Ga e O x±δ , La a Ca b Mn c Al d O x±δ , La a Ca b Co c Al d O x±δ , Ba a Bi b Sn c La d O x±δ , La a Ca b Mn c Co d Ni e Al f O x±δ , Y a Ca b Mn c O x±δ , La a Ca b Fe c Co d O x±δ , and Sr a Na b Sn c YH d O x±δ , where a, b, c, d, e and f are each between 0 and 1, the sum of a through f equals 1 to 3, x is the sum of a through f plus 1, and δ is the vacancy concentration or excess oxygen concentration. 
     
     
         8 . The catalyst system of  claim 1 , wherein the selective hydrogen combustion component is a combination of metal combination (a)(iv) and at least one of oxygen and sulfur. 
     
     
         9 . The catalyst system of  claim 8 , wherein the at least one selective hydrogen combustion component comprises one or more of In a Cu b Mn c O x±δ , Mn a Co b O x±δ , In a Zn b Mn c Al d O x±δ , In a Zn b Mn c O x±δ , Mn a Zn b O x±δ , Mn a Zn b Al c O x±δ , In a Mn b O x±δ , In a Mn b Al c O x±δ , and Mn a Zn b Ti c O x±δ , where a, b, c, and d are each between 0 and 1, the sum of a through d equals 1 to 3, x is the sum of a through d plus 1, and δ is the vacancy concentration or excess oxygen concentration. 
     
     
         10 . The catalyst system of  claim 1 , wherein the selective hydrogen combustion component comprises at least one crystal structure selected from perovskite crystal structure, spinel crystal structure, or birnessite crystal structure. 
     
     
         11 . The catalyst system of  claim 1 , wherein the aromatization component and/or the selective hydrogen combustion component further comprises at least one of at least one support, at least one filler and at least one binder. 
     
     
         12 . The catalyst system of  claim 1 , wherein the aromatization component comprises (i) at least one zeolite molecular sieve and, optionally, (ii) a group 8-14 element or a combination of metals from the same group of the Periodic Table. 
     
     
         13 . The catalyst system of  claim 1 , wherein the aromatization component is in physical admixture with the selective hydrogen combustion component. 
     
     
         14 . The catalyst system of  claim 1 , wherein the aromatization component and the selective hydrogen combustion component are chemically bound.